Enhanced surface geometry sheeting

ABSTRACT

A woven fabric sheeting ( 30 ) includes a plurality of warp yarns ( 32 ) and filling yarns ( 34 ) woven together in a twill weave pattern, with the sheeting ( 30 ) including a plurality of warp yarn floats ( 36 ), and the filling including a synthetic filament yarn. Another woven fabric sheeting ( 40 ) includes a plurality of warp yarns ( 42 ) and filling yarns ( 44 ) woven together in a twill weave pattern, with the sheeting ( 40 ) including a plurality of filling yarn floats ( 46 ), and the warp including a synthetic filament yarn.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is directed to woven fabric sheeting.

2. Description of Related Art

Woven fabric sheeting typically is made of 100% cotton or a combinationof cotton and a synthetic material such as, for example, polyester.Sheeting made entirely of cotton usually is quite comfortable to thetouch. However, such all-cotton sheeting tends to lack long-termdurability. For example, the sheeting may deteriorate at an undesirablyfast rate due to yarn damage from normal washing and use. In contrast,sheeting which includes a synthetic material typically has a higherdurability. However, this feature comes at the expense of comfort.

In an effort to combine comfort features of cotton fabrics withdurability advantages of synthetic fabrics, U.S. Pat. No. 5,495,874(owned by the assignee of the present invention) proposes a plain wovenfabric sheeting constructed of cotton warp yarns and polyester filamentfilling yarns. However, it would be desirable to make that plain weavefabric more comfortable.

Thus, further improvements in woven fabric sheeting are desired.

SUMMARY OF THE INVENTION

I have determined that a woven sheeting construction which includes warpyarn floats and a synthetic filament yarn in the filling is sufficientto provide a woven fabric sheeting with improved levels of comfort anddurability. Such a construction brings a greater proportion of each ofthe floated yarns (i.e., the warp yarns) to the surface of the sheeting,which tends to increase surface tactile comfort. Thus, the floated yarnsmay be said to be “comfort yarns”. At the same time, the syntheticfilament yarn enhances the durability of the sheeting. In addition, theconstruction provides differentially elevated and/or depressed areas ordesigns on the surface of the sheeting, which may create pathways orchannels for increased airflow through and/or across the sheeting. Thisfeature not only enhances comfort, but also is believed to have apositive impact on skin care.

Alternatively, the sheeting may include filling yarn floats and asynthetic filament yarn in the warp. And if desired, the sheeting mayinclude both warp yarn floats and filling yarn floats, with the fillingand/or the warp including a synthetic filament yarn. These constructionsalso achieve the advantages described above.

The woven fabric sheeting may be characterized by a float pattern, x/y,which is specific to a given warp or filling yarn (and/or to a pluralityof warp or filling yarns) as that yarn relates to yarns in theperpendicular direction of the weave. x represents the number ofadjacent yarns (at least two) over which a floated yarn extends or“floats”, and y represents the number of adjacent yarns (at least one)under which the floated yarn passes. Although not required, a floatpattern typically is repeated along the length of a given warp yarn orfilling yarn. The portion of the floated yarn which extends over two ormore adjacent yarns is referred to as a “float”. In general, each of xand y is a whole number greater than zero (0), and x is at least two(2). If a warp or filling yarn does not include floats, then that yarndoes not have a float pattern.

Any of the floated yarns may be formed of natural fibers, syntheticstaple fibers, and/or synthetic filaments. Advantageously, the floatedyarns are natural yarns, for example, cotton yarns to provide the mostdesired comfort. At least one of the yarns which is perpendicular (inthe weave) to a given floated yarn is formed of synthetic filament, forexample, polyester. Advantageously, a plurality of the perpendicularyarns in the sheeting are formed of synthetic filament. If desired, oneor more of the perpendicular yarns may be formed of natural fibersand/or synthetic staple fibers.

The woven fabric sheeting may be constructed using any non-plain weavepattern or combination of such patterns. For example, the sheeting maybe formed using a twill weave, a satin weave, a gabardine weave, aherringbone weave, or a combination of such weaves. In addition, anysuitable yarn float pattern may be used. Nonlimiting examples include a2/1 twill weave pattern, a 2/2 twill weave pattern, and a 4/1 satinweave pattern, although other float patterns and weaves with floatedyarns are possible, as will be appreciated by one of ordinary skill inthe art.

By virtue of the foregoing, there is thus provided a woven fabricsheeting having advantages over prior woven fabric sheetings. These andother advantages of the present invention shall be made apparent fromthe accompanying drawings and description of the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in, and constitute apart of this specification, illustrate versions of the invention, and,together with the general description of the invention given above, andthe detailed description of versions of the invention given below, serveto explain the principles of the invention.

FIG. 1 is a perspective view of a woven fabric sheeting in accordancewith the principles of the invention;

FIG. 2 is an enlarged, fragmentary top view, not to scale, of a portionof a woven fabric sheeting in accordance with the principles of theinvention; and

FIG. 3 is an enlarged, fragmentary top view, not to scale, of a portionof another woven fabric sheeting in accordance with the principles ofthe present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

With reference to FIG. 1, a woven fabric sheeting 10 includes a firstsurface 12 and an oppositely-disposed second surface 14, with thesurfaces 12, 14 extending between a left selvage 16 and a right selvage18, as well as a top or trailing end 20 and a bottom or leading end 22.

With reference to FIG. 2, a woven fabric sheeting 30 includes aplurality of warp yarns 32 and filling yarns 34, with the yarns 32, 34woven together in a twill weave having a warp yarn float pattern of 2/1.In other words, a series of floats, as at 36 a,b,c,d, are staggered inthe filling direction, with the floats being formed by the warp yarns32. As seen in FIG. 2, the 2/1 float pattern simply indicates that eachof the warp yarns 32 extends, or “floats”, over two adjacent fillingyarns, and then passes under a single filling yarn, a pattern which isrepeated along the length of each of the warp yarns 32. The warp yarns32 are natural yarns, for example, cotton yarns; and the filling yarns34 are multifilament yarns, for example polyester multifilament yarns.Because the warp yarns 32 are floated, a greater proportion of each ofthe warp yarns 32 is present at the first surface 12 of the sheeting 30.In contrast, the filament filling yarns 34 are not floated, andtherefore a lesser proportion of each of these yarns 34 is present atthe surface 12. The net effect is an increase in tactile comfort at thesurface 12 and an overall enhancement in durability.

With reference to FIG. 3, a woven fabric sheeting 40 includes aplurality of warp yarns 42 and a plurality of filling yarns 44, with theyarns 42, 44 woven together in a twill weave which includes a pluralityof filling yarn floats, as at 46 a,b,c,d, having a float pattern of 2/1.In this particular sheeting 40, the filling yarn floats are staggered inthe warp direction. In addition, given the 2/1 float pattern, each ofthe filling yarns 44 extends (i.e., “floats”) over two adjacent warpyarns, and under a single warp yarn, with this pattern being repeatedalong the length of each of the filling yarns 44. The warp yarns 42 aremultifilament yarns, for example, polyester multifilament yarns; and thefilling yarns 44 are natural yarns, for example cotton yarns. Becausethe filling yarns 44 are floated, a greater proportion of each of theyarns 44 is present at the first surface 12 of the sheeting 40. Incontrast, the filament warp yarns 42 are not floated, and therefore alesser proportion of each of these yarns 42 is present at the surface12. The result is an increase in tactile comfort at the surface 12 andan overall enhancement in durability.

Each of the woven fabric sheetings described above provides severalbenefits and advantages. For example, the sheeting offers an enhancedlevel of comfort and durability. In addition, air is able to pass acrossor through the sheeting to an extent which not only improves comfort,but also may have a favorable impact on skin care.

In use, the woven fabric sheeting may be formed into suitable items. Forexample, any of the sheetings may be formed into sheets, pillow cases,and the like, all of which are both comfortable and durable.

By virtue of the foregoing, there is thus provided a woven fabricsheeting having advantages over prior woven fabric sheetings.

While the present invention has been illustrated by the description ofversions and specific examples, and while the versions have beendescribed in considerable detail, I do not intend to restrict or in anyway limit the scope of the appended claims to such detail. Additionaladvantages and modifications readily will appear to those skilled in theart. For example, although the drawings illustrate a twill weave, anynon-plain weave may be used, with nonlimiting examples including a twillweave, a satin weave, a gabardine weave, a herringbone weave, andcombinations of such weaves. And although multifilament yarns are usedin the sheeting versions illustrated in FIGS. 2 and 3, a woven fabricsheeting may use monofilament yarns—either in place of, or incombination with, multifilament yarns. In addition, while FIGS. 2 and 3depict sheetings having a single float pattern which is maintainedthroughout the sheeting, as well as floats in only one of the weave(i.e., warp or filling) directions, any suitable float pattern orcombination of float patterns may be used—either in a single weave(i.e., warp or filling) direction or in both (i.e., both warp andfilling) weave directions. The invention, in its broader aspects,therefore is not limited to the specific details, representativeapparatus and methods, and illustrative examples shown and described.Accordingly, departures may be made from such details without departingfrom the scope or spirit of my general inventive concept.

1. A woven fabric sheeting, comprising: a plurality of warp yarns; and aplurality of filling yarns, the warp yarns and the filling yarns beingwoven together in a weave pattern which includes a plurality of warpyarn floats, at least one of the filling yarns including syntheticfilament.
 2. The sheeting of claim 1 wherein the one of the fillingyarns is a synthetic filament yarn.
 3. The sheeting of claim 2 whereinthe synthetic filament yarn is formed of polyester.
 4. The sheeting ofclaim 2 wherein the synthetic filament yarn is a multifilament yarn. 5.The sheeting of claim 1 wherein at least one of the filling yarns is aspun yarn.
 6. The sheeting of claim 5 wherein the spun yarn includesnatural fibers.
 7. The sheeting of claim 6 wherein the spun yarn furtherincludes synthetic staple fibers.
 8. The sheeting of claim 5 wherein thespun yarn includes synthetic staple fibers.
 9. The sheeting of claim 1wherein at least one of the warp yarns is a spun yarn.
 10. The sheetingof claim 9 wherein the spun yarn includes natural fibers.
 11. Thesheeting of claim 10 wherein the spun yarn further includes syntheticstaple fibers.
 12. The sheeting of claim 9 wherein the spun yarnincludes synthetic staple fibers.
 13. The sheeting of claim 1 wherein atleast one of the warp yarns is a synthetic filament yarn.
 14. Thesheeting of claim 1 wherein the warp yarns and the filling yarns arewoven together in a weave pattern selected from the group consisting ofa twill weave, a satin weave, a gabardine weave, a herringbone weave,and combinations thereof.
 15. The sheeting of claim 1 wherein thesheeting has a warp yarn float pattern of 2/1.
 16. The sheeting of claim15 wherein the weave pattern is a twill weave.
 17. A woven fabricsheeting, comprising: a plurality of warp yarns; and a plurality offilling yarns, the warp yarns and the filling yarns being woven togetherin a weave pattern which includes a plurality of filling yarn floats, atleast one of the warp yarns including synthetic filament.
 18. Thesheeting of claim 17 wherein the one of the warp yarns is a syntheticfilament yarn.
 19. The sheeting of claim 18 wherein the syntheticfilament yarn is formed of polyester.
 20. The sheeting of claim 18wherein the synthetic filament yarn is a multifilament yarn.
 21. Thesheeting of claim 17 wherein at least one of the warp yarns is a spunyarn.
 22. The sheeting of claim 21 wherein the spun yarn includesnatural fibers.
 23. The sheeting of claim 22 wherein the spun yarnfurther includes synthetic staple fibers.
 24. The sheeting of claim 21wherein the spun yarn includes synthetic staple fibers.
 25. The sheetingof claim 17 wherein at least one of the filling yarns is a spun yarn.26. The sheeting of claim 25 wherein the spun yarn includes naturalfibers.
 27. The sheeting of claim 26 wherein the spun yarn furtherincludes synthetic staple fibers.
 28. The sheeting of claim 25 whereinthe spun yarn includes synthetic staple fibers.
 29. The sheeting ofclaim 17 wherein at least one of the filling yarns is a syntheticfilament yarn.
 30. The sheeting of claim 17 wherein the warp yarns andthe filling yarns are woven together in a weave pattern selected fromthe group consisting of a twill weave, a satin weave, a gabardine weave,a herringbone weave, and combinations thereof.
 31. The sheeting of claim17 wherein the sheeting has a filling yarn float pattern of 2/1.
 32. Thesheeting of claim 31 wherein the weave pattern is a twill weave.
 33. Awoven fabric sheeting, comprising: a plurality of warp yarns; and aplurality of filling yarns, the warp yarns and the filling yarns beingwoven together in a weave pattern which includes a plurality of warpyarn floats in a 2/1 float pattern, at least one of the filling yarnsbeing a synthetic filament yarn.
 34. A woven fabric sheeting,comprising: a plurality of warp yarns; and a plurality of filling yarns,the warp yarns and the filling yarns being woven together in a weavepattern which includes a plurality of filling yarn floats in a 2/1 floatpattern, at least one of the warp yarns being a synthetic filament yarn.